Adsorption element and methods

#The present invention relates to an adsorption element for removing contaminants from a gaseous stream, such as an air stream.

#Gas adsorption articles or elements are used in many industries to remove airborne contaminants to protect people, the environment, and often, a critical manufacturing process or the products that are manufactured by the process. A specific example of an application for gas adsorption articles is the semiconductor industry where products are manufactured in an ultra-clean environment, commonly known in the industry as a “clean room”. Gas adsorption articles are also used in many non-industrial applications. For example, gas adsorption articles are often present in air movement systems in both commercial and residential buildings, for providing the inhabitants with cleaner breathing air.

#Typical airborne contaminants include basic contaminants, such as ammonia, organic amines, and N-methyl-2-pyrrolidone, acidic contaminants, such as hydrogen sulfide, hydrogen chloride, or sulfur dioxide, and general organic material contaminants, often referred to as VOCs (volatile organic compounds) such as reactive monomer or unreactive solvent. Silica containing reactive and unreactive materials, such as silanes, siloxanes, silanols, and silazanes can be particularly detrimental contaminants for some applications. Additionally, may toxic industrial chemicals and chemical warfare agents must be removed from breathing air.

#Referring now to the drawings, wherein like reference numerals and letters indicate corresponding structure throughout the several views:

#FIG. 1 shows a schematic, perspective view of an adsorptive element according to the present invention;

#FIG. 2 shows an enlarged, schematic, top plan view of a portion of a first embodiment of the adsorptive element of FIG. 1;

#Referring now to the Figures, specifically to FIG. 1, an adsorptive element or article according to the present invention is shown at 10. Adsorptive element 10 is defined by a structured body 12 having a first face 17 and a second face 19 that is positioned a distance “L” from first face 17. That is, body 10 has a thickness “L” between first face 17 and second face 19. Body 12 includes a plurality of cells 14 therein. Preferably, cells 14 are present in a non-random, orderly array. Cells 14 define passages 16 through body 12 that extend from first face 17 to second face 19.

#Referring now to FIGS. 2 and 3, present on the interior walls of cells 14 is an adsorptive coating 20, 20′ that has an adsorptive media 22 retained on cells 14 by a polymeric resin or adhesive 30. Coating 20, 20′ is present within cells 14 yet allows air or other fluid to move through passages 16.

#Adsorptive coating 20, 20′ specifically adsorptive media 22, removes contaminants from the air passing through passages 16 by adsorbing, absorbing, trapping, retaining, reacting, or otherwise removing contaminants from the air stream and transferring them to adsorptive media 22. An adsorptive media 22, such as activated carbon, traps contaminants on its surface or in pores of adsorptive media 22. Depending on the size of the contaminants and the porosity of adsorptive media 22, some contaminants may enter into and become trapped within pores or passages within adsorptive media 22. Typically, the surfaces of the adsorptive media 22 react with the contaminants, thus adsorbing the contaminants at least on the surfaces. Coating 20, 20′ can additionally or alternately have an oxidizing agent. When heat is applied, volatile organic compounds (VOCs) that contact coating 20, 20′ are oxidized into carbon dioxide and water.